Microstructure patterns

ABSTRACT

In one aspect, there is provided a method of creating a microstructure pattern on an exterior surface of an aircraft, boat, automobile or other vehicle is disclosed. A layer of photopolymer (44) is applied to the top coat or substrate (43) by nozzles (45). The photopolymer is selectively irradiated to activate its photoinitiator and the unirradiated polymer is removed. The irradiation can be via a mask (49) which does not come into contact with the polymer, or via a beam splitting arrangement (63, 64) or a diffraction grating (71). The pattern can be formed by either leaving the exposed photopolymer in situ, or using the exposed photopolymer to mask the substrate, etching the substrate, and then removing the exposed photopolymer. In another aspect, there is provided a method 1100 comprising the step 1102 of applying a layer of photocurable material to the exterior surface, the step 1104 of irradiating the photocurable material with radiation including a predetermined irradiation intensity profile, and the step 1106 of removing uncured photocurable material to form the microstructure pattern. The radiation initiates curing of the irradiated photocurable material, causing a curing depth profile across the layer of the photocurable material corresponding to the selected intensity profile.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/767,990, filed Apr. 12, 2018, which is a 35 U.S.C. § 371 nationalstage application of PCT International Application No.PCT/AU2016/050960, filed on Oct. 13, 2016, which claims the benefit ofU.S. Provisional Patent Application No. 62/240,708, filed Oct. 13, 2015.The contents of the above patent application are hereby incorporated byreference in their entirety.

FIELD OF THE INVENTION

The present disclosure relates to a method and a system for patterning amicrostructure on a surface. More particularly, the present disclosurerelates to patterning a microstructure on an exterior surface. In onearrangement, the present invention provides a microstructure pattern ona top coat on an exterior surface of a vehicle.

BACKGROUND

The fuel consumption by modern aircraft depends significantly upon thedrag experienced by the aircraft. Similar considerations apply inrelation to boats and automobiles. It has been known for some time thatthe drag of an aerodynamic surface can be reduced by creating amicrostructure pattern on the surface.

Reference to any prior art in the specification is not, and should notbe taken as, an acknowledgment or any form of suggestion that this priorart forms part of the common general knowledge in any jurisdiction orthat this prior art could reasonably be expected to be understood,regarded as relevant and/or combined with other pieces of prior art by aperson skilled in the art.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention there isdisclosed a method of providing a microstructure pattern on an exteriorsurface of a vehicle, said method comprising the steps of:

-   -   applying a layer of photocurable material to said exterior        surface, said photocurable material including a photoinitiator;    -   selectively irradiating said photocurable material to activate        said photoinitiator in only those regions of the photocurable        material layer irradiated; and    -   removing either the un-irradiated photocurable material or the        irradiated photocurable material,    -   wherein both the applying and irradiating steps do not involve a        mask coming into contact with said photocurable material layer.

Preferably the photocurable material is a photopolymer.

In accordance with a second aspect of the present invention there isdisclosed a method of providing a microstructure pattern on an exteriorsurface, the method comprising the steps of:

-   -   applying a layer of photocurable material to the exterior        surface;    -   irradiating the photocurable material with radiation including a        predetermined irradiation intensity profile to initiate curing        of the irradiated photocurable material, the curing causing a        curing depth profile across the layer of the photocurable        material corresponding to the selected intensity profile; and    -   removing uncured photocurable material to form the        microstructure pattern.

In accordance with further aspects of the present disclosure,corresponding systems for providing a microstructure pattern on anexterior surface are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Arrangements of the disclosure will now be described, by way of exampleonly, with reference to the accompanying drawings in which:

FIG. 1 is a schematic representation of a photopolymer before and afterirradiation;

FIG. 2 is a schematic perspective view of a prior art rollingphotolithography apparatus used in a continuous process to manufacture amicrostructure pattern and in which a mask is in contact with thephotopolymer;

FIG. 3 is a transverse cross-sectional view through the cylinder of theapparatus of FIG. 2;

FIG. 4 is a schematic side elevation of a second prior art techniquewhich may be termed the Fraunhofer technique and in which a webmicrostructure former or mould comes in contact with the photopolymer;

FIG. 5 is an enlarged view showing some details of the arrangement ofFIG. 4;

FIG. 6 is a schematic cross-sectional view of a roller apparatus inaccordance of an arrangement of the present disclosure in which a maskcomes into close proximity to, but not contact with, the photopolymer;

FIG. 7 is an enlargement of a portion of FIG. 6 showing in detail thecomponents thereof;

FIG. 8 is a view similar to FIG. 6 but illustrating an alternativearrangement in which a predetermined intensity profile is provided bymeans of interference of two beams generated by a beam splitter;

FIG. 9 is an enlarged view of the central portion of the apparatus ofFIG. 8; and

FIG. 10 is a schematic illustration of a diffraction gratingillustrating the interference pattern created using such a grating;

FIG. 11A is a flow chart of an example of a method of providing amicrostructure pattern on an exterior surface;

FIG. 11B illustrates side views of outputs of steps of the describedmethod illustrated in FIG. 11A;

FIG. 11C illustrates top views of outputs of steps of the describedmethod illustrated in FIG. 11A;

FIG. 12 illustrates an arrangement of a system for carrying out a stepof the method illustrated in FIG. 11A;

FIGS. 13A to 13C illustrate snapshots of irradiation of a layer ofphotocurable material by the system illustrated in FIG. 12.

FIG. 14A illustrates another arrangement of a system for carrying outthe method illustrated in FIG. 11A;

FIG. 14B illustrates a snapshot of irradiation of a layer ofphotocurable material by the system illustrated in FIG. 14A;

FIG. 14C illustrates yet another arrangement of a system for carryingout the method illustrated in FIG. 11A;

FIGS. 15A-15E illustrate examples of microstructure patterns provided bythe present disclosure; and

FIGS. 16A and 16B illustrate examples of post-processing stepsapplicable to the method of the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates to a technique in providing amicrostructure pattern on an exterior surface, such as on the top coatof a vehicle, such as an aircraft, a boat and an automobile, whichtravels through a fluid such as air or water.

Photocurable materials such as photopolymers are well known fromphotolithographic techniques developed for computer microchipfabrication and, as illustrated schematically in FIG. 1, thephotopolymer 1 consists of a mixture of smaller molecules (monomers 2and oligomers 3) and a photoinitiator 4.

After exposure to ultraviolet light 6, or radiation, normally via amask, the photoinitiator catalyses a polymerization reaction between themonomers 2 and the oligomers 3 causing them to cross-link up into largernetwork polymer molecules and thereby form the cured polymer. Thesenetwork polymers change their chemical and structural properties.So-called “negative photopolymers” become insoluble and stronger thanthe unexposed photopolymer. However, so-called “positive photopolymers”become soluble and thus weaker than the unexposed photopolymer.

Microstructures can thus be made by applying a thin layer ofphotopolymer to a substrate and exposing it to UV light or radiationthrough a photomask. Either the unexposed negative photopolymer isremoved by use of a developer liquid which washes away the unexposedphotopolymer, thereby leaving the exposed photopolymer in the desiredpattern, or the exposed positive photopolymer is removed.

A liquid etchant can then be applied which attacks the substrate but notthe remaining photopolymer. Consequently, when the remainingphotopolymer is removed, the desired microstructure is created etchedinto the substrate. Other etching methods such as by means of a plasma,are also able to be used.

Photolithography Techniques

This general photolithography technique has been used in rolling maskphotolithography in a continuous process as schematically illustrated inFIGS. 2 and 3. Here liquid photopolymer is applied via nozzles 10 to asubstrate 11. A cylindrical rolling mask 12 is rolled over thephotopolymer and contains an internal coaxial source 13 of UV radiation.Downstream of the rolling mask 12 are nozzles 15 for the developer andnozzles 16 for the rinse.

As seen in FIG. 3, UV radiation from the source 13 passes through themask 12 which is in contact with the photopolymer on the substrate 11thereby forming the abovementioned photo polymerization reaction. Thepolymer coated substrate 11 then passes under the nozzles 15 and 16 torespectively remove the unexposed photopolymer from those portions ofthe substrate not covered by an exposed photopolymer and rinse thesubstrate 11.

An alternative process is illustrated in FIGS. 4 and 5. In thisFraunhofer method the microstructure is formed out of the photopolymerand left on the aircraft surface rather than being etched into theaircraft surface, or substrate, as is the case in the prior artarrangement of FIGS. 2 and 3. In the arrangement of FIGS. 4 and 5, a UVtransparent web 22 has a negative of the desired microstructure formedon its outside surface. The web 22 is preferably formed from siliconefilm and is transparent to UV radiation emitted from a UV lamp 21. Theweb 22 passes over a pair of flexible rollers 23 and a guide roller 25.A dosing unit 24 takes the form of a tank 30 and a pipe 31 which permitsa liquid coating 26 to be applied to the web and formed from the liquidcontained in the tank 30. The liquid coating 26 is then applied to theupper surface of the substrate 27 by the rolling motion of the web 22over the rollers 3, 5.

As indicated in FIG. 5, the web 22 has a negative of the desired patternand thus forms the photopolymer 32 on the substrate 27 into that desiredpattern. The UV radiation 33 from the UV lamp 21 passes through the web22 and sets the photopolymer 32 into the desired pattern formed by thecured photopolymer 28. Thus, as the apparatus moves relative to thesubstrate 27 in the direction indicated by arrow 29, so the curedphotopolymer 28 in the desired pattern is formed on the substrate 27.

In this method the rolling mask matrix material requires a very lowsurface energy and a Shore hardness within a specific narrow range. Inaddition, the liquid coating 26 must adhere to the substrate 27 afterexposure yet not run or otherwise change shape after the web 22 isremoved. Furthermore, the web 22 is expensive to produce and degradesthrough the rolling contact process.

Mask-Based Arrangement

Turning now to FIGS. 6 and 7, an arrangement of the present disclosureis described. The apparatus takes the form of a hood or shroud 41 whichcovers the apparatus and protects it from ambient UV light. Within theshroud are a pair of rollers 42 which permit the apparatus to move overa substrate 43.

In an arrangement generally similar to that of FIG. 2, an array ofnozzles 45 apply polymer to the substrate 43, a further array of nozzles46 applies liquid developer and a still further array of nozzles 47applies a liquid rinse. Between the nozzles 45 and 46 is a rollingcylindrical mask 49 which contains a UV light source 50. In analternative arrangement, the mask may be substantially planar and istranslated above and along said exterior surface. A skilled person wouldappreciate that description hereinafter of a cylindrical mask, withminor modifications, may be applicable to a substantially planar mask.

As best seen in FIG. 7, the mask 49 does not come into contact with thephotopolymer 44 but is instead spaced therefrom by a small gap 51 ofapproximately 10-100 centimetres.

As schematically illustrated in FIG. 6, those portions of thephotopolymer 44 which are exposed to the UV radiation from source 50remain adhered to the substrate 43 after passing under the developernozzles 46 and rinse nozzles 47. The present arrangement, which utilisesproximity printing techniques of computer microchip photolithography,can achieve a resolution down to 1-2 microns which is more thansufficient for microstructures which reduce aerodynamic, such as skinfriction drag. The described arrangement allows for differentphotopolymer/developer combinations without the strict requirements formask contact printing as described above in relation to FIGS. 4 and 5.In addition, different cylindrical masks 49 can be easily substituted toallow different microstructure arrangements to be applied, for example,to different areas of the exterior of a single aircraft.

It is also possible to use the arrangement of FIGS. 6 and 7 so as toform the microstructure by etching the substrate 43. This can be done byusing additional etching nozzles, or by immersing an entire panel in theetching liquid.

Maskless Arrangement

In accordance with a further arrangement of the present disclosure, asillustrated in FIGS. 8 and 9, a maskless system can be created by use ofinterference lithography. Interference lithography allows for continuouspatterning of regular arrays by setting up an interference patternbetween two coherent light, or radiation, sources. The minimum spacingbetween features is equal to approximately half the wavelength whichcorresponds to a minimum spacing of approximately 0.2 microns for UVradiation. As indicated in FIG. 8, the apparatus of FIG. 6 is modifiedby the removal of the cylindrical mask 49 and light source 50 and theprovision instead of a UV laser 61, a spatial filter 62, a beam splitter63 and a pair of mirrors 64. In this arrangement, the wavelength for theUV laser is 364 nanometers. The mirrors 64 are moveable relative to thesubstrate 43 so as to increase or decrease the angle θ. This adjusts thespacing between the pattern lines generated by the interferencearrangement.

As before, the present arrangement can be used to form etched patternsinto the substrate 24 by the provision of additional etching nozzles.

Turning now to FIG. 10, the arrangement of FIGS. 8 and 9 can be furthermodified so that instead of using beam splitting techniques, adiffraction grating 71 (e.g. in the form of a phase mask) is utilisedinstead. The diffraction grating 71 is uniformly illuminated from a UVsource (not illustrated in FIG. 10) so as to thereby again form aninterference pattern on the substrate 43. Under this arrangement thespacing pattern is not tunable but is instead determined by theconstruction of the diffraction grating.

Single-Exposure Arrangement

Some existing photolithographic arrangements require multiple-exposureto create a desirable microstructure pattern layer by layer (e.g. bymultiple-exposure) across a surface. Described herein is a method andsystem for providing a microstructure pattern on an exterior surfacethat provides a microstructure pattern with a selected spatial profilewithout the need for multiple-exposure.

As illustrated in FIG. 11A, the described method 1100 comprises the step1102 of applying a layer of photocurable material to the exteriorsurface, the step 1104 of irradiating the photocurable material withradiation including a predetermined irradiation intensity profile, andthe step 1106 of removing uncured photocurable material to form themicrostructure pattern. The radiation initiates curing of the irradiatedphotocurable material, causing a curing depth profile across the layerof the photocurable material corresponding to the selected intensityprofile. The correspondence may include a linear or a non-linearrelationship between the selected intensity profile and the curing depthprofile. The removing step 1106 of may occur after completion of thecuring.

FIGS. 11B and 11C illustrate schematically a side view 1150 and a topview 1160, respectively, of an example of the intermediate or finaloutput after each of steps 1102, 1104 and 1106 of the described method1100. In this example, the layer of photocurable material is aUV-curable or near-UV-curable coating 1152, which upon curing adheres tothe exterior surface. The coating 1152 may be designed for specific use,such as up to military specifications including the MIL-PRF-85285specifications. In another instance, the coating 1152 is primer-surfacerCromax 3130S. In this example, the exterior surface is a substrate 1154,such as the top coat of a vehicle. In the example illustrated in FIGS.11B and 11C, the predetermined irradiation intensity profile is asawtooth irradiation intensity profile 1156. In this example, where theintensity-to-curing-depth correspondence is a linear relationship, theresulting microstructure pattern includes a sawtooth riblet geometry1160. In another example, where the intensity-to-curing-depthcorrespondence is a non-linear relationship, the resultingmicrostructure pattern includes a scalloped riblet geometry.

Microstructure Patterning Systems

FIG. 12 illustrates an arrangement of a microstructure patterning system1200 configured to carry out the irradiating step 1104 in the describedmethod 1100. In this arrangement, the step 1102 of applying the coating1152 to the substrate 1154 (which has already taken place) and the step1106 of removing the uncured photocurable material (which has not yettaken place) are carried out separately and not by the system 1200.

The system 1200 includes a radiation source 1202. The radiation source1202 may be a near-UV light source. In one example, the near-UV lightsource is a 405 nm laser diode with power output of up to 50 mW. Thelaser diode behaves as a point-like source producing in phase incidentlight. This wavelength allows photomasks to be made from glass ratherthan quartz, which would otherwise be necessary for UV wavelengths. Inanother system, other wavelengths may be used. The system 1200 includesa radiation modifier 1203 to modify the radiation to produce desirableirradiation to the layer of photocurable material. In one arrangement,the radiation modifier 1203 includes an amplitude mask 1204 and/or phasemask 1206. To achieve a predetermined irradiation intensity profile, theradiation is passed through an amplitude mask and/or a phase maskassociated with the predetermined irradiation intensity profile. In caseof an amplitude mask 1204, it may be a gray-scale mask, having differenttransparency or attenuation based on position on the mask. In case of aphase mask 1206, it may be in a form of a one-dimensional diffractiongrating providing an interference pattern 1209 upon illumination. Thepredetermined irradiation intensity profile in the presence of bottom-upcuring (see more description below) allows creation of a microstructurepattern without the need for multiple-exposure.

In this arrangement, the irradiation intensity profile has variationsalong a first dimension 1211, causing a curing depth profile withvariations also along the first dimension 1211. The radiation modifier1203 may include a shutter 1208 to limit the exposed area of the layerof the photocurable material 1152 along the first dimension 1211. Theradiation modifier 1203 may also include a photoresist mask 1214 tolimit the exposure along a second dimension 1212, substantiallyorthogonal to the first dimension 1211. The radiation source 1202 and/orthe radiation modifier 1203 are supported by a support rig 1210. Thesupport rig 1210 is configured to displace, such as raising andlowering, the supported components to change the distance from theradiation modifier 1203 to the layer of the photocurable material 1152.The support rig 1210 is also configured to displace, such as translatingalong the second dimension 1212, the radiation source 1202 and theradiation modifier 1203 to irradiate a different part of the layer ofphotocurable material 1152. The displacement of the radiation modifier1203 allows exposure of an area of the layer of photocurable material1152 larger than the aperture of the radiation modifier 1203.

FIGS. 13A to 13C illustrate snapshots of irradiation of a layer ofphotocurable material 1152 by the system 1200 with displacement. Forexample, as illustrated in FIG. 13A, where the photoresist mask 1214and/or the shutter 1208 limit the radiation exposure to a substantiallylinear dimension, the radiation source 1202 and the radiation modifier1203 are translated in a continuous motion along the second dimension1212 to achieve exposure area larger than the aperture of the radiationmodifier 1203. As another example, as illustrated in FIG. 13B, where thephotoresist mask 1214 and/or the shutter 1208 allow more radiationexposure along the second dimension 1212, the radiation source 1202 andthe radiator modifier 1203 are translated in a shuttered manner (i.e.translate-expose-shutter in repeated cycles) along the second dimension1212 to achieve exposure area larger than the aperture of the radiationmodifier 1203. In either example, the periodicity in the curing depthprofile along the first dimension 1211, with or without the support rigtranslation along the second dimension 1212, results in the formation ofone or more of the following microstructure patterns: a sawtooth ribletgeometry (FIG. 15A), a scalloped riblet geometry (FIG. 15B) and a bladeriblet geometry (FIG. 15C). Where the exterior surface is part of avehicle's exterior surface, these geometries are known to reduce theparasitic drag, such as skin friction drag, experienced by the vehicleas the vehicle moves relative to a fluid, such as air or water. Inessence, the microstructure patterns of FIGS. 15A to 15C have the effectof delaying or reducing separation of a fluid boundary layer adjacentthe exterior patterned surface. The relatively delayed or reducedseparation of the fluid boundary layer results in reduced skin frictiondrag. Advantageously, by reducing parasitic drag, the vehicle may, forexample, experience increased fuel efficiency. A person skilled in theart will appreciate that a number of different non-illustratedmicrostructure patterns may have the same effects as those shown inFIGS. 15A to 15C.

FIG. 14A illustrates another arrangement of a microstructure patterningsystem 1400. Unlike the system 1200, the system 1400 is configured toundertake all of steps 1102, 1104 and 1106. The system 1400 includes aphotocurable coating applicator 1402 for applying a photocurablecoating, an irradiator 1404 for irradiating the photocurable materialwith radiation 1403 including a predetermined irradiation intensityprofile, and a remover 1406 for removing uncured photocurable materialto form the microstructure pattern. The irradiator 1404 may include aradiation source 1202 and a radiation modifier 1203. The remover 1406includes a develop applicator 1406 a for applying a developer 1407 a tofacilitate separation of the uncured photocurable material from thecured photocurable material. The remover 1406 also includes a rinseapplicator 1406 b for applying a rinsing agent 1407 b to rinse off theuncured photocurable material. The choice of the developer 1407 adepends on the photocurable material used. For instance, the developercan be a mineral alcohol for UV-curable coatings. In some arrangement,physical removal with compressed air may be possible for somephotocurable materials.

In this arrangement, the system 1400 includes an enclosure 1408 toenclose the photocurable coating applicator 1402, irradiator 1404 andthe remover 1406 positioned in this order. Further, the system 1400includes two wheels, a front wheel 1410 a and a rear wheel 1410 b, toroll on the substrate 1154 (with or without the photocurable material1152). In use, the system 1400 can be rolled in the direction from therear wheel 1410 b to the front wheel 1410 a. The front wheel 1410 a isplaced near the photocurable coating applicator 1402, which carries outthe first step (step 1102) of the described method 1100, whereas therear wheel 1410 b is placed near the remover 1406, which carries out thelast step (step 1106) of the described method 1100.

FIG. 14B illustrates a snapshot in carrying out the method 1100 by thesystem 1400 when rolled on an aircraft surface 1412. The photocurablecoating applicator 1402 applies a photocurable coating 1414 to theaircraft surface 1412. Similar to the illustration in FIG. 12A, thephotoresist mask 1214 and/or the shutter 1208 in the irradiator 1404limit the radiation exposure to a substantially linear dimension with aninterference pattern 1209. As the system 1400 is rolled along thedimension 1212, the photocurable material upon irradiation becomes curedphotocurable material 1416 over time and exhibits a curing depthprofile. The remover 1407 then develops and rinses to remove uncuredphotocurable material 1417 to form a microstructure pattern 1418.

FIG. 14C illustrates a similar arrangement of a microstructure patternsystem 1450 to the system 1400 but without any wheels. In thisarrangement, to achieve an exposure area larger than the aperture of theradiation modifier, the system 1450 includes a robotic arm 1452 whichsupports the enclosure 1408 of the system 1400 (less the wheels 1410 aand 1410 b) and moves in a shuttered (i.e. translate-expose-shutter) ora continuous manner.

In the arrangement of FIG. 12, the radiation modifier 1203 does notprovide any variations in the irradiation intensity profile in thesecond dimension 1212. This permits a periodic curing depth profile withperiodicity (and hence periodic patterning of microstructures) in thefirst dimension 1211 across the layer of irradiated photocurablematerial, as well as a substantially non-periodic profile in the seconddimension 1212. For example, the support rig 1210 may be configured totranslate the radiation source 1202 and the radiator modifier 1203,relative to the substrate 1154 at a constant speed, along the seconddimension 1212 to provide a substantially constant curing depth profilein the second dimension 1212. In another arrangement, the translationspeed may be controlled in a variable fashion to provide a non-constantcuring depth profile in the second dimension 1212, with the varyingtranslation speed corresponding to the non-constant profile in thesecond dimension 1212. Lower translation speeds generally correspond tolarger curing depths and vice versa. For example, a translation speed ina sawtooth fashion may yield an inverse sawtooth curing depth profile inthe second dimension 1212. In yet another arrangement, the translationspeed may be constant but the overall intensity (with or without theintensity profile) may be controlled in a variable fashion to provide anon-constant curing depth profile in the second dimension 1212, with thevarying overall intensity corresponding to the non-constant profile inthe second dimension 1212. Lower overall intensities generallycorrespond to small curing depths and vice versa. For example, anoverall intensity varied in a sawtooth fashion may yield a sawtoothcuring depth profile in the second dimension 1212. As a skilled personwould appreciate that sawtooth or inverse sawtooth profiles areillustrative only, the non-constant curing depth profile can result in avariety of non-constant microstructure pattern a having variation alongthe second dimension. In one example, the height variation can manifestin a tapered riblet geometry, where each riblet includes a sawtoothprofile in one dimension and a ramp-up portion, plateau portion and aramp-down portion in the orthogonal dimension. Other examples can befound in, for instance, U.S. Pat. No. 6,345,791.

In an alternative arrangement, the radiation modifier 1203 may includeanother one-dimensional amplitude or phase mask (not shown) or mayreplace the one-dimensional amplitude or phase mask with atwo-dimensional amplitude or phase mask, to provide variations in theirradiation intensity profile along the second dimension 1212, causing acuring depth profile with variations also along the second dimension1212. In this arrangement, the radiation source 1202 and the radiatormodifier 1203 are translated in a shuttered manner, as illustrated inFIG. 13C, to achieve an exposure area larger than the aperture of theradiation modifier 1203. The periodicity in the curing depth profilealong the first dimension 1211 and the second dimension 1212, with orwithout the support rig translation along the second dimension 1212,results in the formation of one or more of the following microstructurepatterns: a lotus leaf geometry (FIG. 15D) and a superomniphobicgeometry (FIG. 15E). Some of these geometries have a self-cleaningproperty to reduce the cleaning or maintenance requirements of, forexample, an aircraft.

In the geometries shown in FIGS. 15A to 15E, the feature size of suchgeometries can be down to approximately 10 microns and heights up toapproximately 100 microns.

Bottom-Up Curing

In one arrangement, the curing includes bottom-up curing. With referenceto the example illustrated in FIGS. 11B and 11C, bottom-up curing refersto a curing process which begins at a first side of the layer of thephotocurable material proximal to the exterior surface (i.e. the bottomside 1162), and continues towards an opposed, second side distal fromthe exterior surface (i.e. the top side 1164). In the absence ofbottom-up curing, the curing may be instantaneous or near instantaneousupon irradiation. Conversely, bottom-up curing allows curing tospatially progress over time from the bottom side 1162 to the top side1164. The bottom-up curing continues to progress until any one of thefollowing occurs: the uncured photocurable material is removed, thelayer of the photocurable material is fully cured, or the curing isinhibited from progressing any further (see further description below).The maximum height of the microstructure pattern can therefore becontrolled by one or more of following: the thickness of the layer ofthe photocurable material, the timing of removing step 1106, and theextent of inhibited curing.

The bottom-up curing gives rise to areas of control to facilitatecontrol of the curing depth profile and hence provision of themicrostructure pattern. For example, controlling the irradiationintensity and/or duration affects the ultimate curing depth profile andthe subsequent microstructure pattern. In the example illustrated inFIGS. 11B and 11C, the correspondence between the irradiation intensityprofile and the curing depth profile is matched or substantiallymatched. Specifically, the curing depth profile is a sawtooth curingdepth profile 1158 corresponding to the sawtooth irradiation intensityprofile 1156. The sawtooth curing depth profile 1158 is achieved byundertaking the step 1106 of removing the uncured photocurable material.In another example, the correspondence may not be matched orsubstantially matched. For instance, where the photocurable material isirradiated with the sawtooth irradiation intensity profile 1156, and iscontinued to be bottom-up cured after the tips of the saw tooth reachingthe full height of the photocurable material layer, the resulting curingdepth profile may correspond to a trapezoidal profile.

Bottom-up curing may be achieved in one of several ways. In onearrangement, the bottom-up curing relies on the presence of oxygen inthe atmosphere to facilitate the bottom-up curing. In particular, atleast some part of the photocurable material undergoes inhibited curingsupressed by oxygen diffused into the photocurable material. Thediffused oxygen inhibits polymerisation of photoinitiators in thephotocurable material. Under atmospheric conditions, atmospheric oxygendiffuses more into an upper portion (i.e. distal from the exteriorsurface) of the layer of photocurable material and less into a lowerportion (i.e. proximal to the exterior surface) of the layer ofphotocurable material. In this example, the exterior surface may be thatof an aircraft, and the atmospheric oxygen may be provided while theaircraft is held in a hangar. The diffused oxygen and the consequentinhibited curing causes differential curing rates within the layer ofthe photocurable material. The differential curing rates include ahigher curing rate towards the first side and a lower curing rate nearthe second side. Where the coating is relatively thick, the oxygeninhibition may only be measurable or effective to a threshold depth,below which the photocurable material is allowed to cure with no orlittle oxygen inhibition. Below the threshold depth, curing becomes moredifficult because of attenuation of the light/radiation as itpenetrates. This attenuation can be caused by absorption into thepolymer itself and/or absorption by pigmentation in the coating.

In another arrangement, as a skilled person would appreciate, theexterior surface may be placed in a controlled environment having oxygenpressurised at a predetermined level to control the level of oxygendiffusion and hence controlling the inhibited curing. In yet anotherarrangement, as a skilled person would appreciate, the exterior surfacemay be placed in a controlled environment having reduced oxygen level toreduce bottom-up curing or the range over which oxygen penetrates belowthe coating the surface.

Post-Processing

The described method 1100 may further include post-processing steps.Subsequent to formation of the microstructure pattern in step 1106, themethod 1100 may include subtractive processing steps or additiveprocessing steps of at least a part of the substrate 1154 where curedphotocurable material is absent. As illustrated in FIG. 16A, the topdiagram represents an output of the method 1100 after the step 1106. Theoutput has a microstructure pattern formed by cured photocurablematerial 1600 on the top surface of the substrate 1154. The top surfaceof the substrate 1154 also includes areas 1602 where the curedphotocurable material 1600 is absent. With substrative processingillustrated in FIG. 16A, the method 1110 further includes removing someof the substrate 1154 by, for example, etching or sand-blasting the topsurface of the substrate 1154 and subsequently removing the curedphotocurable material 1600. The output of the subtractive processing isa substrate-only material that includes a microstructure patterncorresponding to the microstructure pattern of the output of step 1106.Alternatively, with additive processing illustrated in FIG. 16B, themethod 1110 further includes adding additional substrate material by,for example, depositing the additional substrate material on the topsurface of the substrate 1154 and subsequently removing the curedphotocurable material 1600. The output of the additive processing is asubstrate-only material that includes a microstructure patterncorresponding to (the negative of) the microstructure pattern of theoutput of step 1106.

The described arrangements of FIGS. 6-15 overcome at least some of theproduction difficulties inherent in the arrangements of FIGS. 2-5. Forexample, in one arrangement, the substrate 43 is the top coat of theexterior surface of an aircraft. As another example, the arrangements ofthe system illustrated in FIGS. 12 and 14 allow creation of amicrostructure pattern without the need for multiple-exposure

A characteristic of the roller apparatus, as illustrated in FIGS. 6-10and its contactless nature, is that the roller apparatus can be appliedto complex curved surfaces and to the windows of aircraft, therebyensuring both greater coverage and drag reduction. The rollable system1400 illustrated in FIG. 14A as well as the robotic system 1450illustrated in FIG. 14C and described in corresponding paragraphs alsoprovide a similar characteristic.

The foregoing describes only some embodiments of the present inventionand modifications, obvious to those skilled in the art, can be madethereto without departing from the scope of the present invention.

The term “comprising” (and its grammatical variations) as used herein isused in the inclusive sense of “including” or “having” and not in theexclusive sense of “consisting only of”.

1. A method, comprising: initiating a process of irradiating at least aportion of a layer of photocurable material on a substrate with lightfor curing the photocurable material to initiate curing of thephotocurable material proximate the substrate, wherein the lightcomprises an intensity profile with variations along at least a firstdimension; and ceasing the process of irradiating of the layer ofphotocurable material, to form cured photocurable material within thelayer of photocurable material in a microstructure pattern, the curedphotocurable material having a variable curing height profile relativeto the substrate, including a variable curing height profile acrossmicrostructures in the microstructure pattern.
 2. The method of claim 1,further comprising continuing the process of irradiating at least aportion of the layer of photocurable material after the initiation anduntil the ceasing, whereby the microstructure pattern is formed by asingle exposure of the photocurable material to the curing light.
 3. Themethod of claim 1, further comprising controlling, between theinitiation and ceasing of the process of irradiating the layer ofphotocurable material, at least one of the irradiation intensity andduration to affect the variable curing height profile acrossmicrostructures in the microstructure pattern.
 4. The method of claim 1,comprising ceasing the process of irradiating the layer of phtocurablematerial before the photocurable material has cured the full height ofthe photocurable material.
 5. The method of claim 1, comprising ceasingthe process of irradiating the layer of phtocurable material after thephotocurable material has cured the full height of the photocurablematerial in one part of a microstructure in the microstructure andbefore the photocurable material has cured the full height of thephotocurable material in another part of the same microstructure.
 6. Themethod of claim 1, wherein the light does not comprise substantialintensity variations along a second dimension substantially orthogonalto the first dimension, and wherein the irradiating comprisingirradiating a first portion of the layer of photocurable material andtranslation along the second dimension to irradiate a second portion ofthe layer of photocurable material, different to the first portion,whereby the microstructure pattern comprises a riblet geometry withriblets extending across the first and second portions of the layer ofphotocurable material.
 7. The method of claim 6, further comprisingmaintaining a substantially constant translation speed, to provide aconstant curing depth profile in the second dimension.
 8. The method ofclaim 6, further comprising varying a speed of the translation, toprovide a non-constant curing depth profile in the second dimension. 9.The method of claim 1, further comprising forming the intensity profilewith variations along at least a first dimension passing through a maskspaced apart from the layer of photocurable material by a gap ofapproximately 10 to 100 centimetres.
 10. The method of claim 1, furthercomprising removing uncured photocurable material within the layer ofphotocurable material, thereby exposing at least part of themicrostructure pattern.